Overlap joint for translucent wall panels

ABSTRACT

THIS INVENTION RELATES TO A JOINT STRUCTURE IN THE NATURE OF A CHANNEL FOR RECEIVING, LOCATING AND MAINTAINING THE ABUTTING EDGES OF AN ADJACENT TRANSLUCENT WALL PANEL. THE OVERLAP CHARACTER OF THIS JOINT PROVIDES FOR THE FIRST TIME, INSOFAR AS KNOWN TO ME, A WEATHER-TIGHT SEAL FOR TRANSLUCENT BUILDING PANELS.

Jan. 19, 971 G. P. REED 3,555,755

- 'pVERLAP-Jom'r FOR TRANSLUCENT WALL PANELS Filed Nov 20, 1968 2 Sheets-Sheet -1 10a l' 10b 10 I [NYE/V701? 76a GEORGE 7? my,

Jan. 19, 1971 e. P. REED III 5515 ovmmr Joxm fox 'rmsnucm um. wmns Filed Nov. 20. 1968 2 Sheets-Sheet 2 T INVENTOE seams R559 United States Patent U.S. Cl. 52-308 5 Claims ABSTRACT OF THE DISCLOSURE This invention relates to a joint structure in the nature of a channel for receiving, locating and maintaining the abutting edges of an adjacent translucent wall panel. The overlap character of this joint provides for the first time, insofar as known to me, a weather-tight seal for translucent building panels.

This invention relates generally to improvements in light diffusing structural panels, and more particularly relates to a joint structure for locating and maintaining adjacent ones of such panels in prescribed relation to one another when conjoined in abutting edge-to-edge relation, especially for roof structures.

In the current state of the art, light diffusing structural panels (of the type disclosed in U.S. Pat. No. 2,931,468) when used as exterior curtain walls for buildings are joined by a batten system, typically illustrated by and described in U.S. Pat. No. 3,082,849. Although various embodiment of this joining system are employed with most forms of translucent, sandwich type curtain walls, in virtually all such cases the conjoined adjacent panels are rigidly held in position by the forcible compression of batten components against the juxtaposed interior and exterior panel edge portions and usually include an interposing layer of resinous sealant between opposed surfaces or the batten and panel in an attempt to maintain weather integrity. Such an arrangement results in certain disadvantages materially affecting the desired Weather integrity of the panel joints in that cyclic temperature variations influence the expansion and contraction of such a joint assembly resulting often times in random ruptures of this sealant leading to a breakdown of the joint integrity. In recent years, the development of sealants which maintain elastic properties even in severe temperature extremes has helped this problem somewhat. However, in a conventional prior art batten system, there is virtually no way by which to achieve a uniform compression along the batten structure for a period of years which then results in a rupture of sealant, with the attendant problems which affect weather integrity.

Further, the necessity for using a batten type joining system incurs extra costs in terms of added material, i.e., for the battens and fasteners, and extra costs in terms of labor for erecting and maintaining this batten system.

It should be noted that the use of conventional battens, by their very design, attempt to hold a panel system in place by the application of clamping forces acting on the marginal edges only of adjoining panels. Expansion and contraction of such batten-joined panels permits any one or more of a series of such panels to shift or slide, thereby getting out of alignment resulting in an aesthetic discontinuity, and/or causing ruptures in the weather seal properties at the batten seam itself.

This disclosure described a novel improvement over the prior art by generally providing a panel construction in which the structural edge portions intermediate the opposed panel surfaces are provided with means for receiving, locating, and maintaining a prescribed non-sliding Patented Jan. 19, 1971 spatial relation between abutting panel edges and into which sealant can be evenly distributed and maintained within the joint assembly. Further, this novel panel edge design also provides an integral overlay surface which extends for a short distance beyond the joint and over the adjoining panel somewhat as a shingle or lap as a further measure of joint protection. By placing this joint structure along the edge portion intermediate the panel surfaces, thereby eliminating the exposed batten system of the prior art type, translucent wall panel buildings may now be erected in areas of corrosive environments which were heretofore closed to building techniques employing exposed aluminum members. For example, in communities with large chemical operation, or those with paper manufacturing operations which expel large quantities of sulphur components into the atmosphere, an exposed metallic batten system was soon so corroded that the structural integrity degraded and the aesthetic appearance of the metallic trim was completely destroyed. Though the translucent panels themselves were unaffected by such corrosive atmospheres, all exposed aluminum joint structures were soon pitted and corroded.

Futher, the provision of an internal joint structure producing a shingle or lap joint overcomes perhaps the largest, single limiting disadvantage to prior art translucent building construction techniques, namely, that with an exposed batten system, the architect or erector has no choice but to orient the panel construction with a visible vertical batten assembly joint. Any other orientation with conventional joints results in serious problems of weather integrity, particularly from rain and snow, due to the damming effect of the batten joint producing a protruding surface discontinuity. Accordingly, where heretofore the erection of translucent wall panels necessitated a vertical joint orientation, the novel battenless shed or lap type joint of this disclosure permits a horizontal joint orientation of panels materially improving the aesthetic features of the building, and simultaneously providing that kind of joint which assures positive weather integrity at all times thereby making this joint especially adaptable for roof structures. Further, this novel joint feature, when employed as a siding in a horizontal fashion, exposes the entire building surface to a washing action which avoids the unsightly effects of so-called drip-line disfigurment due to repeated coursing of drip-water along a given path. Such a washing action has utility in rinsing off radioactive contamination from laboratories and other buildings which batten-type erection obviously cannot offer.

It is accordingly among the many objects of this invention to provide an improved curtain-wall panel having an edge portion adapted for receiving, locating and maintaining an adjoining roof or wall panel edge in a prescribed relation thereto.

It is a further object of this invention to provide a curtain-wall panel assembly which virtually dispenses with an exposed metallic batten structure and the attendant problems of atmospheric corrosion.

A still further object of this invention is to provide a panel joint assembly which can be employed with equal confidence on horizontally inclined surfaces, as well as vertical surfaces with assurance that the joint structure will maintain its weather integrity under virtually all circumstances for a period of years.

It is yet a still further object to provide a curtain-wall panel joint wherein at reasonable distance therefrom, an observer would not see a joint, the entire wall or roof surface for all intents and purposes appearing as if without joints at all.

A feature of this invention is that in climates of alternate freezing and thawing, the overlap characteristic of this joint assembiy eliminates any dam effect should these panels be employed as a roof structure.

A further feature of this invention is that less sealant need be employed because only one side of the panel joint need carry any sealant material.

A still further feature of this invention is that by eliminating the conventional batten system which requires four sealant barriers, i.e., two on each panel surface, and employing instead the novel joint structure of this disclosure which requires only one sealant barrier, we have thus reduced the leak potential at any joint by a factor of probably 1015 times what can be currently expected.

With these and other objects and features in view as will hereinafter more fully appear, and which will be more particularly pointed out in the appended claims, reference is now made to the following description taken in conjunction with the accompanying drawings in which:

FIG. 1 illustrates as one example, a plan view of a roof portion of a building utilizing a plurality of curtain wall panels using the novel joint assembly of this invention;

FIG. 2 illustrates in enlarged perspective view the detail of the joint structure at the edge of a typical panel used in FIG. 1;

FIG. 3 illustrates the separate panels with my joint structure before assembly used to make the roof shown in FIG. 1;

FIG. 4 illustrates a side elevation view taken on line 4-4 of FIG. 1 showing the assembled panels supported on a roof rafter;

FIG. 5 illustrates a side elevation view along one edge of a typical panel employing my novel joint taken on line 55 of FIG. 3;

FIG. 6 illustrates in enlarged section a portion of the assembled point taken on line 66 of FIG. 1;

FIG. 7 illustrates another embodiment of this joint structure adapted for use as a roof;

FIG. 8 illustrates in enlarged section similar to FIG. 6 a portion of an alternate form of the assembled joint shown in FIG. 7; and

FIG. 9 illustrates another embodiment of this joint structure as applied to a vertical wall.

In FIG. 1, there is shown a plan view of a typical pitched roof section comprised of panel members 10a, 10b, and 100 suitably conjoined in accordance with the disclosure of this invention in abutting edge-to-edge relation, and conventionally fastened by screws or adhesive means along their side edges to a supporting framework of rafters. These panels are typically 4 to 5 feet wide, and may span 12 or more feet in length. Partial sections are generally illustrated in this disclosure since the point of novelty resides in the edge structure of these panels and the mode of fitting them together. As shown in these drawings, particularly FIG. 2, the joint structure itself is a metallic, preferably aluminum, extrusion 13 comprising a plurality of right angularity related structural members 14, 15, 16, and 17. The end portion 16a of member 16 is angularly bent in the direction of surface 17 for reasons hereinafter explained. This extrusion member 13 is co-extensive with and suitably fastened to the full length of the panel edge as shown in FIG. 5 by any conventional mechanical fastening means 19, as for example, rivets or screw members. Member 14 carries a surface protrusion or spacer 18 along its entire length as shown in FIG. 5 for reasons hereinafter explained.

Referring now to FIG. 6, there is illustrated in enlarged detail the abutting roof panels, 10b, 100 of FIG. 1. As more fully disclosed in US. Pat. No. 2,931,468, these wall panels themselves are comprised generally of a core structure of inter-locked I-beam elements right-angularly disposed with respect to one another and on whose opposed flanged surfaces are laminated resinous facing sheets of translucent fiber-reinforced material. In FIG. 6, the peripheral I-beam members running lengthwise of each of the panels 10b, 100 are designated, respectively 20, 21 and the opposed flanged surfaces of each I-beam are designated, respectively, 22, 23, and 24, 25. The translucent overlay sheets are shown as 26, 27, and 28, 29.

As depicted in FIG. 6, a joint member 13b is attached to the full length of the outer edge of I-beam 20 by fasteners 19b in such a fashion that the outer surface of arm 14b is coplanar and co-extensive with the flange surface 23. Thus when translucent overlay sheet 27 is laminated into position, it will extend from the I-beam surfaces over arm 14b to its edge thereof. Similarly, joint member is attached in like fashion by fasteners 19c to edge of I-beam 21, and similarly overlay sheet 28 will extend to the edge portion thereof also. Accordingly, as seen in FIG. 6, as adjoining panels 10b and 10c are brought into abutting relation, facing sheet 29 of panel 10c rides on spacer ridge 18b until the panel edge as represented by I-beam 21 comes into touching contact with the terminal point 16b of the structural member 16 carried by panel 10b. Similarly, facing sheet 26 or panel 10b rides on spacer 18c until the panel edge 20 comes into touching contact with terminal point 16c of the structural member 16 carried by panel 10c. Thus, in light of this disclosure, it can be seen from FIG. 6, that panels 10b, 10c, when fitted together are held in predetermined spaced relation, i.e., by the coaction of terminal points 16b and acting against their respective abutting panel edge surfaces, and these panel edges are also held in position laterally by the coaction of spacer ridges 18b, 18c acting in conjunction against opposed facing sheets 26 and 29.

Prior to abutting the panel edges together, a measured amount of flexible sealant 32 is depostied on either side of each ridge 18b, 18c whereby when the panels are fitted together, the spatial separation between, for example, facing sheet 29 and structural member 14b would be filled with such sealant. Because this spatial relation is uniform along the full length of the panel edge, and will remain uniform because of the stop effect of spacer 18b, a rupture or break in the sealant because of expansion or contraction or other flexure, is highly remote, thus assuring continuous weather integrity for this joint over a period of years.

FIG. 7 illustrates a different embodiment showing panels 10a and 10e where the joint assembly exists on only one side of abutting panel edges. This embodiment would appear as shown in enlarged section in FIG. 8. The joint assembly is substantially the same as disclosed in FIG. 6 with the exception that the joint 13 is carried on one side of the panel only. Though the opposed panel edge portions 35 of panel 10d and 36 of panel 10e are without any apparent connection, this is in no way detrimental from a structural point of view as far as panel assembly is concerned. The spaced relation between 35, 36 may be considered an inconvenience from the point of view of dust ultimately finding its way interiorly thereof, however, this is easily remedied by the insertion of a resilient material such as sponge rubber or plastic insert 37, if so desired.

FIG. 9 illustrates still another embodiment of this joint structure, as for examples where panels are erected in a vertical orientation as for walls. In this arrangement, the joint structure is located on the exterior or weatherside of the wall assembly so that only alternate panels, e.g., 10g need carry joint members, since panels 10 and 10h are fitted into each joint member 13.

It should be fairly obvious in light of this disclosure that because of the overlap character of this joint assembly, panel assemblies could readily be adapted for inclined roof structures in which successive joints would be oriented in a horizontal shingle-like fashion to shed rain, in addition to a similar orientation for wall-sidings.

The particular embodiment of the invention herein chosen for illustration and description are exemplary of a variety of combinations of the structural features disclosed and it will, accordingly, be understood that various changes in the details, materials, steps and arrangements of parts herein described and illustrated may be made by those skilled in the art within the principles and scope of the invention as expressed in the appended claims.

Having thus described my invention, I claim:

1. In a building enclosure comprised of a series of translucent sandwich type panels having peripheral lip portions positioned in edge overlapped relation, and wherein each panel is comprised of reticulated structural grid core assembly carrying this translucent sheet material on its opposed surfaces thereof, the combination thereof with:

(a) a structural joint member carried on the longitudinal edge of a panel;

(b) said joint member comprising channel means for receiving and locating the peripheral lip portion of an adjacent panel structure;

(c) spacer means located within said channel means for maintaining a uniform clearance between the surface of the inserted panel structure, and the opposed surface of the channel means; and

((1) stop means forming a part of said channel means for limiting the insertion distance of an adjacent panel.

2. The structure of claim 1 wherein a flexible sealant is inserted into the aforementioned uniform clearance on each side of the spacer means.

3. The structure of claim 1 wherein the joint memher is attached to its respective panel so as to have the exterior surface of its channel means lie in a plane coextensive with the surface of the structural core of said panel and wherein said channel means is overlaid by its respective translucent sheet material.

4. The structure of claim 1 wherein the aforesaid joint member comprises a structural channel means including: (a) an elongated generally U-shaped channel portion; (b) spacer means located longitudinally along the opposed inner surface of one of the arms of said U- shaped channel portion; and (c) the terminal end portion of the other arm of said U-shaped channel positioned to a predetermined distance from the bottom of the said U-shaped portion. 5. The structure of claim 1 wherein a foam rubber insert is carried between said adjoining panels oppositely from said structural joint member.

References Cited UNITED STATES PATENTS 1,844,961 2/1932 Kramer 52553 2,358,396 9/1944 Hogan 52394 2,740,166 4/ 1956 Siering 52 -553 2,741,001 4/1956 De Martin 52307 2,931,468 4/1960 Keller 52663' 3,082,849 3/1963 Keller 52204 3,408,786 11/1968 Snyker 52394 2,220,690 11/1940 Stupakoif 52308 FOREIGN PATENTS 742,402 9/ 1966 Canada 52394 HOWARD C. SUTHERLAND, Primary Examiner U.S. Cl. X.R. 52394, 519, 553 

